Features:

PRETREATMENT EQUIPMENTS

Equipments used in the preliminary stages of water treatment.

• Multimedia Filters
• Activated Carbon Filters
• Micron Filters
• Bag Filters

 

ION EXCHANGE SYSTEMS
Equipments used, to reduce minerals and hardness in water.

• Softners
• Demineraliser
• Mixed Bed

 

MEMBRANE SYSTEMS
Equipments used to polish the water to desired levels of process requirements.

• Reverse Osmosis Systems [Single and Double Pass]
• Nanofiltration
• Ultrafiltration
• Electro de ionization

 

MICROBIOLOGICAL TREATMENT EQUIPMENT
Equipments used, wherein microbiological activity is deterrent to the final product or process.

• Chemical Dosing Systems
• Ultraviolet Sterilisers
• Ozonators
• Absolute Micron Filtration

 

For critical water generation and distribution projects in the pharmaceutical industry for USP grade systems we provide -

 

For System Manufacturing and Integration,

• URS/FRS/FATS, Process Safety Analysis [PSA], Process Safety Management [PMS] Programs.

For System Commissioning and Validation

• GMP Audit, SOP Development, O & M and PM Manuals and Training, DQ/IQ/ /OQ/ PQ Equipment

For Industry Compliance

• ISO,ASTM, NCCLS, PHARMACOPOEIA

Design Basis

• A typical Water Treatment Plant

The water prior to entering the downstream RO unit is passed through a 5 micron (nominal rated) cartridge filter for achieving reduction of particulate matter, which could otherwise clog the RO membranes. The cartridges are of disposable type.

 

 

Mode of Operation

The plant is designed to be operated in automatic mode completely controlled by PLC. All basic interlocks based on level will be provided to protect the drives. The control philosophy forms a part of our offer.

Design of water treatment plant is based on your Raw Water Analysis Report /Parameters. Change in the parameters of raw water analysis will affect the performance of the plant in terms of the quality and quantity.

Chlorine Dosing System

 To reduce the organic fouling in raw water. The incoming raw water is dosed with Sodium Hypochlorite solution. The dosing of chemical is carried out by means of a chemical dosing system. The chemical dosing system comprises of a HDPE tank, solenoid operated diaphragm dosing pump, inbuilt low level switch and a chemical injection assembly. A retention time of 30 minutes in the raw water storage tank will help the Sodium Hypochlorite solution to reduce the microbial content in water.

Raw Water Tank

To store the raw water to be treated in the system 

Raw Water Pump

To boost water pressure from raw water tank and deliver to pretreatment at pressure and volume required.

Multi Media Filter

To filter sand and sediment (turbidity). The water enters sand filter from top and gets filtered through carefully selected graded sand. The suspended solids are trapped / arrested by the sand media and these are removed / drained during backwash of the sand filter. The sand filter is recommended to be backwashed once a day or on attaining a differential pressure of 0.8 kg/cm².  The treated water at the outlet of the sand filter will have suspended solids of < 5 ppm.

Softener [1W]

The water entering the softener contains Calcium and Magnesium which has a scaling tendency in the presence of Alkalinity. The softener unit contains cationic resin in Sodium form. This resin exchanges the calcium and magnesium from water and give out sodium, which does not form scale. The softener has to be regenerated with common salt on a predetermined output per regeneration

SMBS Dosing System 

Filtered water is dosed with Sodium Meta Bi Sulphate solution. Sodium Meta Bi Sulphite helps in neutralizing the free chlorine content in water. The dosing of chemical is carried out by means of a chemical dosing system. The chemical dosing system comprises of a HDPE tank, solenoid operated diaphragm dosing pump, inbuilt low level switch and a chemical injection assembly. Free chlorine if present in water can de-cross link ion exchange resins and oxidize membranes which may be located downstream. Generally an ORP meter is considered for detecting free chlorine and is located downstream of dosing the chemical.

Soft Water Tank 

To store the raw water to be treated in the system 

Ultra filtration Unit

The Ultra Filtration membrane considered is of hollow fiber type having a molecular cut off at 100,000. The Ultra Filtration process is a cross flow type technology. The hollow fiber membrane allows water to pass through while rejecting (arresting) bacteria, particulate matter, colloids which is drained off. The membranes can be back flushed on a predetermined time or differential pressure. Generally a recovery of 90% is obtained.

Ultrafiltration Water Tank

To store the raw water to be treated in the system 

RO Feed Water Pump 

To boost water pressure from raw water tank and deliver to pretreatment at pressure and volume required.

pH Correction System

The water is dosed with NaoH or other alkaline chemical to increase the pH of the water, to make it of suitable pH at the outlet. A pH analyzer is used to control the dosing

Antiscalant Dosing System

The water is dosed with an Antiscalant, which helps in arresting the scale forming tendency of water. This is done by sequestering the scale forming compounds. The dosing of chemical is carried out by means of a chemical dosing system. The chemical dosing system comprises of a HDPE tank, solenoid operated dosing pump, inbuilt low level switch and a chemical injection assembly.

5 Micron Filters

Reverse Osmosis Unit [Chemical Sanitizable]

The Reverse Osmosis Block comprises of Pressure Tube and Spirally Wound Membranes. The Reverse Osmosis process is of cross flow type. When water is fed to the membranes reject most of the minerals present in water are rejected and only a portion is allowed to pass through in the product water. Thus you have three streams in a Reverse Osmosis System. One is feed, second is rejecting (concentrate) and third is permeating (product water). The RO unit is designed for a recovery of 60 %

• High Pressure pump of Grundfos or equivalent. The pump will be in SS 316 construction working at a pressure of 10 to 12 bar. The flow rate shall be 2,000 lph.
• 5 nos. High performance membranes of 4” diameter and 40” long, of Hydranautics, OR Thin Film Composite DOW, USA or equivalent make, will be supplied
• Membrane Housings will be of high pressure SS 316.
• Valves and Sampling Points.
• Pressure Switches.
• Pressure gauges in SS 316
• Flow meters [3 nos] for feed, permeate and concentrate flow
• Conductivity meter
• Input water flow rate will be 2000 lph and output permeate flow rate will be 1200 lph and output concentrate output will be 800 lph.
• Controlled through the PLC system

EDI (Chemical Sanitizable)

The Water from RO Outlet is passed through Electro Deionization (EDI) Unit.  The EDI Unit will further polish the TDS (conductivity) and ensure the purified water conductivity as per the USP standards.

Voltage applied across each cell forces migration of contaminants out to the feed water into the reject stream.  The resin is continuously regenerated.

• EDI is a continuous Electro-Deionization process that uses:
• Ion exchange resin
• Ion selective membranes
• DC electricity as a driving force to produce high-quality DI water

Continuous Electro-deionization (EDI) removes ions from water using ultra-pure ion exchange resin. Multiple beds of ion-exchange material are arranged in narrow rectangular spaces (Dilute, or “D” chambers) contained between sheets of ion-exchange membrane. The deionization takes place in this resin bed, much as in conventional mixed-bed ion exchange. Water does not pass through the membranes, only ions do.

Alternating between the D chambers are narrow spaces called the Concentrate, or “C” chambers.  Each layer of resin, membrane and associated spaces is called a cell. A group of cells is arranged in series, and electrodes within terminal Electrode or “E” Chambers are located at both ends.

The key difference between EDI and conventional DI systems lies in the method used for resin regeneration. In EDI, regeneration is achieved by using a DC voltage to create a current through the resin bed. Because each bead of resin touches an adjacent bead, the ions can migrate from one bead to the next in the direction of the electrode. The DC voltage then, draws Cations towards the cathode and anions towards the anode. As the ions reach the membrane they can pass into the C chamber but cannot move any further towards the electrode, they are blocked by the adjoining membrane containing resin possessing the same fixed charge. The voltage involved can be up to 220V per cell.

The inlet area of the bed is in the unregenerate state. Ions are taken up by the resin and removed by being transferred towards the membrane. There is an additional mechanism occurring within the stack. At the outlet end of the resin bed there are insufficient ions remaining in the water to sustain the applied current. Here the DC electrical energy splits water into H⁺ and OH^‑, maintaining the resin in a regenerated state. For removal of weakly charged ions, such as silica, it is essential to use efficient electric current to maintain the resin in a highly regenerated state.

• EDI will be Ion pure or equivalent
• Product outflow will be 1000 lph
• Recovery 90%
• The EDI will be Chemical Sanitary type
• Valves and Sampling Points.
• Sampling valves
• pH meter
• conductivity meter
• Controlled through the PLC system

Ultraviolet Sterilizer

To eliminate microbial count if any from the purified water

Product Storage Tank

The product tank is to store product water and also is used for raising the temperature of water during hot water sanitization

Product Water Pump

To boost water pressure from product Storage tank and deliver to point of use at pressure and volume required.

CIP Tank

• Capacity of the tank will be 1000 liters
• MOC will be HDPE
• Level sensors
• Controlled through the PLC system

CIP Pump

To boost water pressure from CIP water tank and deliver to pretreatment at pressure and volume required.

5 Micron Filters

The water after the CIP tank unit is passed through a 5 micron (nominal rated) cartridge filter for achieving reduction of particulate matter. The cartridges are of disposable type.

Piping (set)

The interconnecting piping for the water treatment system along with valves and other fittings shall be in SS 316l after the soft water tank. In pretreatment it shall be in UPVC

Skid

The water treatment system, except for the tanks and product pumps and piping shall be skid mounted. This will make the unit compact and will be easy to operate.

The skid shall be of SS 304 construction. The skid will be supplied with leveling screws. The panel shall be mounted on the skid, and complete interconnection shall be provided within the panel to enable ease of operation, and prevent any accidents.

Control Panel

The control panel shall be in SS 304 construction

The PLC shall be Allen Bradley or equivalent

Display of 5.8” size, touch screen, Colour

Printing facility

Suitable interlocking for the system with alarm indications

Single phase preventers etc

Instrumentation

The instrumentation will be of the following make

• The pH, ORP, conductivity meters will be Emersons
• Flow meter from Khrone Marshal
• Pressure Transmitters of Keller
• Semi-Automatic Valves will be with Crane actuators.
• Temperature Transmitters of Radix

Additional Points

• The product surfaces will be passivized
• Weld coupons will be provided
• Piping will be orbital welded wherever possible.

Termination Points

• Inlet of Raw water Pump.
• Backwash, Drain outlet of Sand filter, Softener, UF and RO
• Reject outlet of UF, RO & EDI system.
• Drain outlet of CIP tank
• Outlet of Product Water Pump
• Drain, Overflow, of all tanks and vessels.
• Chemical and dilution water inlet to all dosing systems.
• Power input control panel.

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